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Electrical Connectors & Housings

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What are Electrical Connectors?

Electrical connectors are critical components that connect or disconnect electrical circuits. There are many types of electrical connectors, some that are one-piece connectors and two-piece connectors that have a plug and socket, along with other connector configurations.

Connectors can be found in almost everything around us, from a simple power tool to the cars we drive. The semiconductor industry uses a wide range of connectors, including integrated circuit sockets, board-to-wire, and board-to-board connectors. Two-piece connectors can be found in all electrical appliances with the plug that connects to a wall socket or the plug used to charge a hybrid car.

Connectors and electrical housings are found throughout electrical systems in the alternative energy, aerospace, oil & gas, medical industries, and many others. Connectors allow for the control and safe delivery of electricity flow and are essential components that play a critical role in making much of our modern-day technology function.

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What are Common Electrical Connectors & Housings Materials?

Electrical Connectors Housings Plastics Machined Rod Injection Molding

Electrical connectors require electrically conductive materials, like copper alloys, beryllium copper, and other metals often coated with gold, nickel, and tin to conduct electricity. They also need electrical insulative materials to contain electricity with high dielectric strength, good dimensional stability and handle a wide range of temperatures and other requirements depending on the application. Plastics, composites, ceramics, and glass are all common materials used for the insulative components for electrical connectors and housings.

Why Plastics & Composites for Electrical Connectors & Housings?

Plastics & composites are ideal for insulative components for housings and electrical connector applications through their ease of manufacturing. Plastics and composites offer various options for cost-effective processes that include high volume machining and a variety of injection molding options that include insert and over-molding.

Depending on the electrical connector or housing application, there is a wide range of plastics & composites to choose from that are electrically insulative and offer excellent dimensional stability, high dielectric strength, UL 94 5V or V-0 flammability.

Common Plastics & Composites Properties for Electrical Applications Sorted by Dielectric Strength

Material	Dielectric Strength	Max Operating Temp.	CLTE	Flammability	Tensile Strength
CPVC Corzan ® Gray	1,250 V/mil	93 °C / 200 °F	3.7 x 10^-5 in./in./°F	UL94 V-0	8,200 psi
G-11 FR-5 Glass Epoxy Laminate	900 V/mil	180 °C / 356 °F	0.55 x 10^-5 in./in./°F	UL94 V-0	43,000 psi
ULTEM ™ 1000 Natural Unfilled PEI	830 V/mil	171 °C / 340 °F	3.1 x 10^-5 in./in./°F	UL94 V-0	16,500 psi
G-10 FR-4 Glass Epoxy Laminate	800 V/mil	140 °C / 284 °F	0.55 x10^-5 in./in./°F	UL94 V-0	45,000 psi
ULTEM ™ 2300 30% Glass Filled PEI	770 V/mil	171 °C / 340 °F	1.1 x 10^-5 in./in./°F	UL94 V-0	17,000 psi
Nylatron 4.6	635 V/mil	149 °C / 300 °F	5.0 x 10^-5 in./in./°F	UL94 HB	15,000 psi
Phenolic LE Linen Laminate	625 V/mil	125 °C / 257 °F	1.8 x 10^-5 in./in./°F	UL94 HB	13,000 psi
PEEK HT High Temperature	584 V/mil	249 °C / 480 °F	2.2 x 10^-5 in./in./°F	UL94 V-0	16,500 psi
Celazole ® U-60 Unfilled PBI	580 V/mil	343 °C / 650 °F	1.3 x 10^-5 in./in./°F	UL94 V-0	23,000 psi
Torlon ® 4203 Electrical Grade PAI	580 V/mil	260 °C / 500 °F	1.7 x 10^-5 in./in./°F	UL94 V-0	18,000 psi
Vespel ® Polyimide SP-1 Unfilled	560 V/mil	260 °C / 500 °F	3.0 x 10^-5 in./in./°F	UL94 V-0	12,500 psi
Phenolic CE Canvas Laminate	550 V/mil	125 °C / 257 °F	2.0 x 10^-5 in./in./°F	UL94 HB	10,000 psi
PVC Gray Type I	544 V/mil	60 °C / 140 °F	6.1 x 10^-5 in./in./°F	UL94 V-0	7,500 psi
PPS Unfilled Virgin	540 V/mil	218 °C / 540 °F	2.8 x 10^-5 in./in./°F	UL94 V-0	13,500 psi
Noryl ® 30% Glass Filled PPO	530 V/mil	104 °C / 220 °F	1.4 x 10^-5 in./in./°F	UL94 V-0	17,800 psi
PEEK GF30 - 30% Glass Filled	500 V/mil	249 °C / 480 °F	1.2 x 10^-5 in./in./°F	UL94 V-0	15,000 psi
Noryl ® Unfilled PPO	500 V/mil	104 °C / 220 °F	3.3 x 10^-5 in./in./°F	UL94 V-0	9,600 psi
PEEK Unfilled Virgin Natural	480 V/mil	249 °C / 480 °F	2.6 x 10^-5 in./in./°F	UL94 V-0	16,000 psi
Sustakon ® PK Polyketone	480 V/mil	120 °C / 248 °F	6.1 x 10^-5 in./in./°F	UL94 HB	8,818 psi
GPO-3 Glass Polyester Laminate	450 V/mil	160 °C / 320 °F	2.0 x 10^-5 in./in./°F	UL94 V-0	9,000 psi
Nylon Type 6/6	400 V/mil	99 °C / 210 °F	5.5 x 10^-5 in./in./°F	UL94 V-2	12,000 psi

Why Plastics & Composites the Boedeker Way for Electrical Connectors & Housings?

We have you covered from material to finished machined or molded parts and everything in between. We specialize in plastics and composites and stand ready to assist with an unmatched inventory of sheet, rod, or tube, CNC machined, injection molded parts, JIT supply, and technical services.

Plastics & Composites Sheet, Rod & Tube Inventory

We stock all commercially available grades of plastic and composite materials for electrical connector and housing applications in sheet, rod, and tube and offer cut to size, same-day shipping on all inventoried plastic and composite materials. Our entire inventory of plastics and composites are coded for full traceability; we offer manufacturer certs. and C of C’s upon request at the time of order for all orders.

ISO Certified CNC Plastics & Composites Only CNC Machining

We specialize in ISO-certified CNC machining of plastic and composite electrical connectors and housings and produce CNC machined parts in prototype to production quantities.

ISO Certified Injection Molding

In addition, we offer injection molding for higher part volume requirements, including over-molded and insert-molded electrical connectors.

Supply Services & Technical Support

For clients that have ongoing part requirements, we offer just-in-time (JIT) delivery with our customer inventory services.

We also specialize in technical services for electrical connectors and housing plastics and composite materials and parts, including selection by application, improved part design assistance, onsite consultation, and more. We stand ready to put our 1,800 years of combined experience and services to work for you.

As an alternative to onsite consultation, we offer our TelePlastics™ remote support service. This is a safe and secure remote solution, for the diagnosis and recommendation of plastic solutions, by our experienced Technical Service staff, utilizing the latest in telecommunication technology.